Solar Mirror Array System, Methods and Apparatuses Thereto

ABSTRACT

An apparatus for transferring force to a frame of a solar mirror array. The frame has at least one structural element. The apparatus includes a torque plate. The apparatus includes at least one node attached to and in contact with the plate which connects with the structural element. An apparatus for attaching a primary solar mirror frame array with a secondary mirror frame array. A solar trough frame for holding solar mirrors.

CROSS -REFERENCE TO RELALED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.15/957,486 filed Apr. 19, 2018, now U.S. Pat. No. 10,648,699, which is adivisional of U.S. patent application Ser. No. 13/598,963 filed Aug. 30,2012, now U.S. Pat. No. 9,951,971 issued Apr. 24, 2018, which is anon-provisional of U.S. provisional application Ser. No. 61/573,275filed Sep. 2, 2011, and claims priority therefrom, and is acontinuation-in-part of U.S. patent application Ser. No. 13/135,137filed Jun. 27, 2011, and is a continuation-in-part part of U.S, patentapplication Ser. No. 12/927,812 filed Nov. 24, 2010, and is acontinuation-in-part of U.S. patent application Ser. No. 12/798,757filed Apr. 10, 2010, and is a continuation-in-part of U.S. patentapplication Ser. No. 12/587,043 filed Sep. 1, 2009, all of which arecontinuations-in-part of, and which this application is acontinuation-in-part of, U.S. patent application Ser. No. 12/583,787filed Aug. 26, 2009, which claims the benefit from U.S. provisionalapplication Ser. No. 61/190,573 filed Aug. 29, 2008, all of which areincorporated by reference herein.

These concepts build upon the following WES patent applications all ofWhich are incorporated by reference herein:

1. Ser. No. 12/583,787

2. Ser. No. 12/587,043

3. Ser. No. 12/798,757

4. Ser. No. 12/927,812

5. Ser. No. 13/135,137

FIELD OF THE INVENTION

The present invention is related to components of CSP (ConcentratedSolar Power) frames including node, strut end piece, chord and beamdesigns and alternative methods of attaching these to their associatedstruts, chords, beams and nodes; it also covers elements of torque platedesigns, solar frame alignment tools and a design to clean dust or sandfrom mirrors without the use of water (limited resource in and regions).(As used herein, references to the “present invention” or “invention”relate to exemplary embodiments and not necessarily to every embodimentencompassed by the appended claims.) Some of inventions, such as the useof cast or impact extruded strut/chord/beam end pieces fastened and/orbonded to longer structural members, have applicability to fields beyondCSP (in fact, to any potential structural application).

BACKGROUND OF THE INVENTION

This section is intended to introduce the reader to various aspects ofthe art that may be related to various aspects or the present invention.The following discussion is intended to provide information tofacilitate a better understanding of the present invention. Accordingly,it should be understood that statements in the following discussion areto be read in this light, and not as admissions of prior art, CSP(Concentrated Solar Power), particularly the parabolic trough utilityscale facilities, are a proven source of renewable energy. Florida Powerand Light operates a facility in the Mojave Desert which has operatedfor decades, which is based on a steel framework supporting theparabolic mirrors. Parabolic mirrors focus sunlight on an oil filledtube, and the hot oil is transferred to a conventional steam electricalpower plant (the hot oil boils the water to steam, which drives theturbines).

Nevada Solar One (NSO) came on line a few years ago the first newparabolic trough CSP plant in the US since the Mojave Desertinstallation. NSO used aluminum extrusions, fabricated and assembledinto mirror support frames instead of structural steel. Continuedinstallation of these types of CSP utility scale operations requirescontinual development in the technologies to improve performance andreduce costs.

The WES solar frame designs (see prior VES patent applications notedabove (Cross-Reference to related applications), incorporated byreference herein) incorporate improvements in the extruded and otherprofiles and components and in the way that they are combined into aframework to support the mirrors. These improvements yield a moreefficient system—from profiles that are more easily extra able at awider variety of available extrusion operations through parts that areeasily fabricated and assembled, utilizing the unique designopportunities provided by the aluminum extrusion process and by otherprocessing and joining techniques discussed in this patent applicationwhich work to both enhance performance and reduce the overall cost ofthe final installation.

BRIEF SUMMARY OF THE INVENTION

The present invention pertains to an apparatus for transferring force toa frame of a solar mirror array. The frame has at least one structuralelement. The apparatus comprises a torque plate. The apparatus comprisesat least one node attached to and in contact with the plate whichconnects with the structural element.

The present invention pertains to a method for transferring force to aframe of a solar mirror array. The frame has at least one structuralelement. The method comprises the steps of attaching a node to a torqueplate. There is the step of attaching the structural element to the nodeof the frame which supports solar mirrors.

The present invention pertains to an apparatus for attaching a primarysolar mirror frame array with a secondary mirror frame array. Theapparatus comprises a primary torque plate having an upper portion and abottom. The apparatus comprises a secondary torque plate having an upperportion and a bottom. The apparatus comprises a torque plate bearing,attached to the primary and secondary torque plate through an attachmentflange of the primary and secondary torque plate. The primary andsecondary torque plates attach to an end of the primary and secondaryframe, respectively, via nodes of the frames that fasten to the upperportions and the bottom of the respective plates. The flange between theprimary and secondary torque plates allows for rotational alignmentbetween the primary and secondary torque plates.

The present invention pertains to a solar trough frame for bolding solarmirrors. The frame comprises a plurality of chords which include a toplayer of only 4 chords essentially in parallel with each other. Theframe comprises a plurality of struts. The frame comprises a pluralityof nodes that connect to the struts and chords. The frame comprises aplatform supported by the chords and struts on which the solar mirrorsare disposed.

The present invention pertains to a method of forming a solar troughframe for holding solar mirrors of a solar frame array. The methodcomprises the steps of attaching a first strut to a top layer having atleast 4chords essentially in parallel with each other. There is the stepof attaching a second strut to the top layer upon which a platform issupported and on which the mirrors are disposed.

The present invention pertains to a structural element fir a supportframe for solar mirrors of a solar array. The structural elementcomprises a strut end piece. The structural element comprises a strut.The structural element comprises adhesive disposed between the strut andthe strut end piece which fixedly attaches the strut and the strut endpiece together.

The present invention pertains to a structural element for a supportframe for solar mirrors of a solar array. The structural elementcomprises a strut end piece. The structural element comprises a strutfixedly attached with solid phase bonds to the strut end piece formedfrom strut and strut end piece without any additional solder or weldmaterial.

The present invention pertains to a method for attaching a strut and astrut end piece together. The method comprises the steps of placing thestrut end piece in contact with the strut. There is the step ofrotational welding the strut end piece to the strut.

The present invention pertains to a method for attaching a strut and astrut end piece together. The method comprises the steps of placing thestrut end piece in contact with the strut. There is the step of frictionstir welding the strut end piece to the strut.

The present invention pertains to an apparatus for cleaning mirrors of asolar mirror array on a support frame having pylons from a vehicle. Theapparatus comprises a blower assembly mounted on the vehicle. Theapparatus comprises a blower mounted on the assembly that blows air at amirror of the array when the vehicle is positioned alongside the mirror,the assembly moving the blower up and down.

The present invention pertains to an apparatus for aligning alongitudinal member. The apparatus comprises a holder having anadjustment mechanism that fits with ,a first end of the firstlongitudinal member which holds a laser. The apparatus comprises areceiver that fits with a second end of the longitudinal member. Thereceiver has a grid upon which light from the laser shines. Theadjustment mechanism adjusted so the light from the laser is centeredabout an axis, of the longitudinal member.

The present invention pertains to a method for aligning longitudinalmembers between two solar frames so the two solar frames are aligned.The method comprises the steps of fitting a holder having an adjustmentmechanism which holds a laser with a first end of a first longitudinalmember of a first frame. There is the step of fitting a receiver with asecond end of the first longitudinal member, the receiver having a gridupon which light from the laser shines, the adjustment mechanismadjusted so the light from the laser is centered about an axis of thefirst longitudinal member. There is the step of removing the receiverfrom the first longitudinal member. There is the step of placing thereceiver into a first end of a second frame's longitudinal member sothat the second frame can be aligned to the first frame.

The present invention pertains to a node for connecting struts andchords of a support frame for solar mirrors of a solar mirror array. Thenode comprises a solid central portion having a first end to which thechord is attached and which chord has an axis along its lengthsubstantially in alignment with a longitudinal axis of the centralportion. The central portion has fins which extend from the centralportion. The fins define at least two pairs of parallel spaced opposingsubstantially flat surfaces. The surface of each pair is spacedequidistantly from a center plane between them to which a strut isattached to each pair.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

In the accompanying drawings, the preferred embodiment of the inventionand preferred methods of practicing the invention are illustrated inwhich:

FIG. 1 shows an impact extrusion SEP (strut end piece) for I.D. strutadhesion—Side View

FIG. 2 shows an impact extrusion SEP (strut end piece) for I.D. strutadhesion—Cross-section view

FIG. 3 shows an impact extrusion SEP for I.D. strut adhesion—ISO view

FIG. 4 shows an impact extrusion SEP for I.D. strut adhesion and strutassembly—Apart

FIG. 5 shows an impact extrusion SEP for I.D. strut adhesion and strutassembly—Joined

FIG. 6 shows an impact extrusion SEP for O.D. strut adhesion—Side view

FIG. 7 shows an impact extrusion SEP for O.D. strutadhesion—Cross-section view

FIG. 8 shows an impact extrusion SEP for O.D. strut adhesion—ISO view

FIG. 9 shows an impact extrusion SEP for O.D. strut adhesion—bottom view

FIG. 10 shows an impact extrusion SEP for O.D. strut adhesion and strutas—Apart

FIG. 11 shows an impact extrusion SEP for O.D. strut adhesion and strutassembly Joined

FIG. 12 shows an impact extrusion SEP for O.D. strut adhesion, strut &node assembly

FIG. 13 shows an impact extrusion SEP for O.D. strut adhesionalternative design Cross-section view

FIG. 14 shows an impact extrusion SEP for O.D. strut adhesionalternative design—ISO view

FIG. 15 shows an impart extrusion Strut/chord end piece variant—ISOfront view

FIG. 16 shows an impact extrusion Strut/chord end piece variant—ISO hackview

FIG. 17 shows an impact extrusion Strut chord end piece variant assembly

FIG. 18 shows an extruded & drilled hollow node fin adaptor—End View

FIG. 19 shows an extruded & drilled hollow node fin adaptor—Side View

FIG. 20 shouts an extruded & drilled hollow node fin adaptor

FIG. 21 shows an extruded & drilled hollow node fin adaptor variant

FIG. 22 shows an extruded & drilled hollow node end adaptorassembly—Apart

FIG. 23 shows an extruded & drilled hollow node end adaptorassembly—Joined

FIG. 24 shows an impact extrusion SEP & strut prior to Inertia FrictionWelding

FIG. 25 shows an impact extrusion SEP & strut attached by InertiaFriction Welding

FIG. 26 shows an impact extrusion SEP & strut prior to Friction StirWelding

FIG. 27 shows an impact extrusion SEP & strut attached by Friction StirWelding

FIG. 28 shows a BEP (beam end piece)—Side View

FIG. 29 shows a REP (beam end piece)—Front View

FIG. 30 shows a REP (beam end piece)—ISO view

FIG. 31 shows a BEP (beam end piece) & beam assembly—Apart

FIG. 32 shows a REP (beam end piece) & beam assembly—Joined

FIG. 33 shows a BEP (beam end piece) & node assembly

FIG. 34 shows a BEP (beam end piece) FEA—Von Mises Stress

FIG. 35 shows a BEP (beam end piece) FEA—Displacement

FIG. 36 shows a two-piece SEP 1 for pins or adhesive—End view

FIG. 37 shows a two-piece SEP 1 for pins or adhesive—Side View

FIG. 38 shows a two-piece SEP 1 for pins or adhesive—ISO view

FIG. 39 shows a two-piece SEP 1 adaptor for pins or adhesive—End view

FIG. 40 shows a two-piece SEP 1 adaptor for pins or adhesive—ISO view

FIG. 41 shows a two-piece SEP 1 & adaptor sub-assembly—Apart

FIG. 42 shows a two-piece SEP 1 & adaptor sub-assembly—Joined

FIG. 43 shows a two-piece SEP 1, adaptor & strut assembly

FIG. 44 shows a two-piece SEP 2 for pins or adhesive

FIG. 45 shows a two-piece SEP 2 for pins or adhesive—ISO view

FIG. 46 shows a two-piece SEP 2 adaptor for pins or adhesive—End view

FIG. 47 shows a two-piece SEP 2 adaptor for pins or adhesive—ISO view

FIG. 48 shows a two-piece SEP 2 & adaptor sub-assembly—Apart

FIG. 49 shows a two-piece SEP 2 & adaptor sub-assembly—Joined

FIG. 50 shows a two-piece SEP 2, adaptor & strut assembly—Apart

FIG. 51 shows a two-piece SEP 2, adaptor & strut assembly—Joined

FIG. 52 shows a two-piece SEP 3 for pins or adhesive—End view

FIG. 53 shows a two-piece SEP 3 for pins or adhesive—ISO view

FIG. 54 shows a two-piece SEP 3 & adaptor sub assembly—Apart

FIG. 55 shows a two-piece SEP 3 & adaptor sub assembly—Joined

FIG. 56 shows a two-piece SEP 3, adaptor & strut assembly—Apart

FIG. 57 shows a two-piece SEP 3, adaptor & strut assembly—Joined

FIG. 58 shows a two-piece SEP 4 for pins or adhesive—End view

FIG. 59 shows a two-piece SEP 4 for pins or adhesive—ISO view

FIG. 60 shows a two-piece SEP 4 & adaptor sub-assembly—Apart

FIG. 61 shows a two-piece SEP 4 & adaptor sub-assembly—Joined

FIG. 62 shows a two-piece SEP 4, adaptor & strut assembly—Apart

FIG. 63 shows a two-piece SEP 4, adaptor & strut assembly—Joined

FIG. 64 shows a two-piece SEP 5 for pins or adhesive

FIG. 65 shows a two-piece SEP 5 for pins or adhesive—ISO view

FIG. 66 show a two-piece SEP 5 adaptor for pins or adhesive

FIG. 67 shows a two-piece SEP 5 adaptor—ISO view

FIG. 68 shows a two-piece SEP 5 alternative adaptor—ISO view

FIG. 69 shows a two-piece SEP 5 & alternative adaptor sub assembly—Apart

FIG. 70 shows a two-piece SEP 5 & alternative adaptor subassembly—Joined

FIG. 71 shows a two-piece SEP 5, alt adaptor & strut assembly—Apart

FIG. 72 shows a two-piece SEP 5, alt adaptor & strut assembly—Joined

FIG. 73 shows a Series 7 frame showing 4 top chords—ISO view

FIG. 74 shows a Series 7 frame showing 4 top chords—front view

FIG. 75 shows a two-piece double torque plate J—front view

FIG. 76 shows a two-piece double torque plate J—ISO view

FIG. 77 shows a two-piece double torque plate J—connection detail

FIG. 78 shows a two-piece double torque plate J—rear connection detail

FIG. 79 shows a two-piece double torque plate J lifting fixture—End ViewBack

FIG. 80 shows a two-piece double torque plate J lifting fixture—End viewFront

FIG. 81 shows a two-piece double torque plate J lifting fixture—ISO view

FIG. 82 shows a two-piece double torque plate J & lifting fixtureassembly

FIG. 83 shows a two-piece double torque plate J & lifting fixtureassembly detail

FIG. 84 shows a two-piece double torque plate J—one side only—ISO view

FIG. 85 shows a two-piece double torque plate J—one side only detail

FIG. 86 shows a two-piece double torque plate J alternative connectionplate

FIG. 87 shows a two-piece double torque plate N

FIG. 88 shows a two-piece double torque plate N—ISO view

FIG. 89 shows a two-piece double torque plate N—Side view

FIG. 90 shows a one-piece double torque plate N

FIG. 91 shows a one-piece double torque plate N—ISO view

FIG. 92 shows a one-piece double torque plate N—ISO view detail

FIG. 93 shows a one-piece double torque plate N1

FIG. 94 shows a one-piece double torque plate N1—ISO view

FIG. 95 shows a torque plate pin with adjustable plate—Front view

FIG. 96 shows a torque plate pin with adjustable plate—ISO view

FIG. 97 shows a torque plate pin with non-adjustable plate—Front view

FIG. 98 shows a torque plate pin with non-adjustable plate—ISO view

FIG. 99 shows a torque plate pin mount plate

FIG. 100 shows a torque plate & pin with adjustable plate assembly

FIG. 101 shows a double torque plate with adjustable pin plates—sideview

FIG. 102 shows a double torque plate without adjustable pin plates—sideview

FIG. 103 shows a Frame Laser Alignment Tool Holder—Front ISO View

FIG. 104 shows a Frame Laser Alignment Tool Holder—Side View

FIG. 105 shows a Frame Laser Alignment Tool Holder—Back ISO View

FIG. 106 shows a Frame Laser Alignment Tool Holder—With Laser

FIG. 107 shows a Frame Laser Alignment Tool Receiver—ISO View

FIG. 108 shows a Frame Laser Alignment Tool Receiver—Front View

FIG. 109 shows a Frame Laser Alignment Tool Receiver—Side View

FIG. 110 shows a Frame Laser Alignment Tools—Showing Laser Beam Betweenthem—Back ISO view

FIG. 111 shows Frame Laser Alignment Tools—Showing Laser Beam Betweenthem—Front ISO view

FIG. 112 shows Solar Frames with Frame Laser Alignment Tools in place

FIG. 113 shows a Mirror blower assembly print—Top View

FIG. 114 shows a Mirror blower assembly print—Back View

FIG. 115 shows a Mirror blower assembly print—Side View

FIG. 116 shows a Mirror blower assembly print—Front View

FIG. 117 shows a Mirror blower assembly print—ISO View Bottom

FIG. 118 shows a Mirror blower assembly print—ISO View Top View

FIG. 119 shows a Mirror blower assembly print—Detailed camera andproximity senor view

FIG. 120 shows a Mirror blower assembly print—Detailed guide rail view

FIG. 121 shows a Mirror dust blower—mounted to side of truck—Front View

FIG. 122 shows a Mirror dust blower—mounted to side of truck—Detailedhead View—Front

FIG. 123 shows a Mirror dust blower—mounted to side of truck—Top View

FIG. 124 shows a Mirror dust blower—mounted to side of truck —Back View

FIG. 125 shows a Mirror dust blower—mounted to side of truck—Detailedhead View—Back

FIG. 126 shows a Mirror dust blower—mounted to side of truck—ISO Viewfrom Back

FIG. 127 shows a Mirror dust blower—mounted to side of truck—ISO Viewfrom front

FIG. 128 shows a Mirror dust blower—mounted to side of truck—Side View

FIG. 129 shows a Mirror dust blower Solar frame—Back View

FIG. 130 shows a Mirror dust blower & Solar frame—ISO View 1

FIG. 131 shows a Mirror dust blower & Solar frame—ISO View 2

FIG. 132 shows a Hollow node torque plate

FIG. 133 shows a Hollow node torque plate connection with node

FIG. 134 shows a Hollow node torque plate connection without node

FIG. 135 shows an Up-dated Solid node torque plate connection (welded)

FIG. 136 shows an Up-dated Solid node torque plate connection(welded)—Top IS node detail

FIG. 137 shows an Up-dated Solid node torque plate connection(welded)—Bottom center node detail

FIG. 138 shows a Solid node torque plate connection (top IS).

FIG. 139 shows a Solid node torque plate connection (bottom centernode).

FIG. 140 shows a Bottom center solid node FEA—Von Mises Stress

FIG. 141 shows a Bottom center hollow node FEA—Von Mises Stress

FIG. 142 shows a Bottom center solid node FEA—Displacement

FIG. 143 shows a Double fin solid node print—Front view

FIG. 144 shows a Double fin solid node—ISO view

FIG. 145 shows a Double fin solid node with strut—Front view

FIG. 146 shows a Double fin solid node with strut—ISO view

FIG. 147 shows a Double fin hollow node FEA, showing deformed hollowcenter portion—Von Mises Stress

FIG. 148 shows a Double fin hollow node FEA—Displacement

FIG. 149 shows a Double fin solid node FEA—Von Mises Stress

FIG. 150 shows a Double fin solid node FEA—Displacement

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings wherein like reference numerals refer tosimilar or identical parts throughout the several views, and morespecifically to FIGS. 75-102, 113 and 133 thereof, there is shown anapparatus 67 for transferring force to a frame 58 of a solar mirrorarray. The frame 58 has at least one structural element, such as a strut16 or a chord 60. The apparatus 67 comprises a torque plate 68. Theapparatus 67 comprises at least one node 22 attached to and in contactwith the plate 68 which connects with the structural element.

The node 22 may have at least one fin 24 extending from the node's outersurface. The node 22 may have a solid central portion. The torque plate68 can withstand a force greater than 1,800 lbs. The torque plate canwithstand a minimum torque load of about 150,591 in-lbs, The plate 68thickness may be about 9/16″.

The present invention pertains to a method for transferring force to aframe of a solar mirror array. The frame has at least one structuralelement. The method comprises the steps of attaching a node to a torqueplate. There is the step of attaching the structural element to the nodeof the frame which supports solar mirrors.

The present invention pertains to an apparatus 77 for attaching aprimary solar mirror frame 58 array with a secondary mirror frame 58array. The apparatus 77 comprises a primary torque plate 72 having anupper portion and a bottom. The apparatus 77 comprises a secondarytorque, plate 74 having an upper portion and a bottom. The apparatus 77comprises a torque plate bearing 76 attached to the primary andsecondary torque plates through an attachment flange 80 of the primaryand secondary torque plate. The primary and secondary torque platesattach to an end of the primary and secondary frame, respectively, vianodes 22 of the frames 58 that fasten to the upper portions 79 and thebottom 81 of the respective plates. The flange 80 between the primaryand secondary torque plates allows for rotational alignment between theprimary and secondary torque plates.

The primary torque plate 72 may have an attachment flange 80 and thesecondary, torque pate 74 may have a marching hole 82 pattern to that ofthe primary torque plate's 72 attachment flange 80, and the bearing 76is attached to the primary and secondary torque plates through theattachment flange 80 of the primary and secondary torque plates. Theapparatus may include a first lifting bracket 88 attached to the primarytorque plate 72 and a second lifting bracket 88 attached to thesecondary torque plate 74 for lifting the frame 58 via the primary andsecondary torque plates. The primary torque plate 72 may have a crossshape. The upper portion 79 of the primary torque plate may have a firstcross arm 83 and a second cross arm 85.

The present invention pertains to a solar trough frame 58, as shown inFIGS. 73 and 74, for holding solar mirrors 122. The frame 58 comprises aplurality of chords which include a top layer 6 of at least 4 chords 60,or alternatively only 4 chords 60 essentially in parallel with eachother. The frame 58 comprises a plurality of struts 16. The frame 58comprises a plurality of nodes 22 that connect to the struts 16 andchords 60. The frame 58 comprises a platform 123 supported by the chords60 and struts 16 on which the solar mirrors 122 are disposed.

The four chords 60 of the top layer may have axial force limits of aminimum of about 500 lbs. The frame 58 may include a torque plate 68having two connections to the top layer of chords 60. At least one ofthe four chords 60 of the top layer 61 may be one continuous piece thatextends the frames entire length. Alternatively, at least one of thefour chords 60 of the top layer 61 is formed of segmented chords 28 thattogether extend the frame's entire length. The four chords 60 of the toplayer 61 may have axial force limits of a maximum of about 20,674 lbs.

The present invention pertains to a method of forming a solar troughframe for holding solar mirrors of a solar frame array. The methodcomprises the steps of attaching a first strut to a top layer having atleast 4 chords essentially in parallel with each other. There is thestep of attaching a second strut to the top layer upon which a platformis supported and on which the mirrors are disposed.

The present invention pertains to a structural element for a supportframe for solar mirrors of a solar array. The structural elementcomprises a strut end piece. The structural element comprises a strut.The structural element comprises adhesive disposed between the strut andthe strut end piece which fixedly attaches the strut and the strut endpiece together.

The element, may include guides disposed between the strut and the strutend piece to provide spacing for the bonded joint. The strut wallthickness may be between 0.035 and 0.250″ and the strut end piecethickness may be between 0.050 and 1.000″. Together the strut and thestrut end piece form a joint that can withstand loads up to between 20and 20,000 lbs. The element may include a fastener which also attachesthe strut and the strut end piece. No fastener may be used to attach thestrut and the strut end piece.

The present invention pertains to a structural element for a supportframe for solar mirrors of a solar array. The structural elementcomprises a strut end piece. The structural element comprises a strutfixedly attached with solid phase bonds to the strut end piece formedfrom strut and strut end piece without any additional solder or weldmaterial.

The present invention pertains to a method for attaching a strut and astrut end piece together. The method comprises the steps of placing thestrut end piece in contact with the strut. There is the step ofrotational welding the strut end piece to the strut.

The present invention pertains to a method for attaching a strut and astrut end piece together. The method comprises the steps of placing thestrut end piece in contact with the strut. There is the, step offriction stir welding the strut end piece to the strut.

The present invention pertains to an apparatus for cleaning mirrors of asolar mirror array on a support frame having pylons from a vehicle. Theapparatus comprises a blower assembly mounted on the vehicle. Theapparatus comprises a blower mounted on the assembly that blows air at amirror of the array when the vehicle is positioned alongside the mirror,the assembly moving the blower up and down.

The blower assembly may automatically position itself relative to thepylons, frames and mirrors. The apparatus may include an impactavoidance mechanism disposed on the vehicle to avoid impact by thevehicle with the pylons, frames and mirrors as the vehicle moves.

The present invention pertains to an apparatus for aligning alongitudinal member. The apparatus comprises a holder having anadjustment mechanism that fits with a first end of the firstlongitudinal member which holds a laser. The apparatus comprises areceiver that fits with a second end of the longitudinal members. Thereceiver has a grid upon which light from the laser shines. Theadjustment mechanism adjusted so the light from the laser is centeredabout an axis of the longitudinal member.

The present invention pertains to a method for aligning longitudinalmembers between two solar frames so the two solar frames are aligned.The method comprises the steps of fitting a holder having an adjustmentmechanism which holds a laser with a first end of a first longitudinalmember of a first frame. There is the step of fitting a receiver with asecond end of the first longitudinal member, the receiver having a gridupon which light from the laser shines, the adjustment mechanismadjusted so the light from the laser is centered about an axis of thefirst longitudinal members. There is the step of removing the receiverfrom the first longitudinal member. There is the step of placing thereceiver into a first end of a second frame's longitudinal member sothat the second frame can be aligned to the first frame.

The present invention pertains to a node for connecting struts andchords of a support frame for solar mirrors of a solar mirror array. Thenode comprises a solid central portion having a first end to which thechord is attached and which chord has an axis along its lengthsubstantially in alignment with a longitudinal axis of the centralportion. The central portion has fins which extend from the centralportion. The fins define at least two pairs of parallel spaced opposingsubstantially flat surfaces. The surface of each pair is spacedequidistantly from a center plane between them to which a strut isattached to each pair.

In the operation of the present invention, the description of thepresent invention, which follows, incorporates further improvements tothe WES designs, covering the node 22, strut 16, strut end piece 10,chord, chord end piece 36, beam 46, beam end piece 38, torque plate 68,torque plate nodes, torque plate 68 alignment and adjustments and othercomponents of the frame design and means to join these componentstogether as needed for the design; a water free mirror 122 cleaningsystem is also disclosed. Separately and together these enhancementsyield the improved designs, performance and costs.

SEP (Strut End Piece) 10/Strut 16 & CEP (Chord End Piece) 36/Chordterminology can often be used interchangeably; the location of the partdetermines what it's called (chords, whether single long pieces orsegmented, often refer to the space frame members that extend along thelongitudinal direction of the frame while struts 16 are members that arenot along this direction).

The prior patent applications included (but are not limited to) thefollowing:

Mirror 122 Support Structures using tubes loaded axially

Modified I-beams as mounting means for Mirror 122 Support Structures

Configuration of Main Supports/Longitudinal Members and Connectors

Strut Designs

Strut end piece 10 concept and design

Means of fastening Strut end piece 10 to Connectors-vs-pins, rivets,bolts or other fasteners, flat-to-flat

Fabrication and Assembly methodology

Automatic mirror 122 cleaning water collection/reclamation system

Single Fin Sleeve

Guided insertion Strut end piece 10

Swaged Strut End Connection

Angled “Knuckle” Hinge Connector

Additional Alternative Strut 16 and Strut end piece 10 Designs

Hollow Single Fin node 22

Hollow Single Fin node 22 design utilizing chord and chord end piece36-vs-through chord (more detail on node 22 designed to best accommodatethe hollow single fins)

Torque plate 68 solid node 22 design

Rolling Rib Location concepts

Other design elements:

-   -   Beam 46 and Beam end piece 38 Connector design    -   Angled Beam 46 with Beam end piece 38 on one end/bracket on the        top, eliminating extra pieced beyond Nodes A&B    -   Mirror 122 Support Rail and Bracketry designs    -   Mirror 122 rail to mirror 122 bracket designs    -   Mirror 122 rail to Beam 46 connection designs    -   Collector Tube Upright connection designs    -   Pin and clip designs

This patent application includes (but is not limited to) the following:

a Different designs of strut end piece 10 designs (extruded, cast, dieeast, impact extruded, etc.) single and multiple piece designs

Different designs of chord end pieces 36

Different designs of beam end pieces 38

Alternative fastening of strut end pieces 10 to strut ends (andsegmented chord 28 end pieces to chord ends) via

-   -   adhesives, pinning, riveting, bolting, or other fasteners (may        not be flat-to-flat)    -   Inertia Friction Welding    -   friction stir welding

WES series 7 frame utilizing 4 top chords 60

Various torque plate 68 design details with node 22, fastening andadjustment designs

-   -   One-piece double torque plate 68    -   Two-piece double torque plate 68    -   Hollow node 22 connection design    -   Welded solid node 22 connection design

Frame Laser 114 alignment tool holder & receiver 120 and methodology foruse

Mirror blower design for cleaning mirrors 122 without using water

Element Summary:

10—SEP

12—SEP fin

14—SEP attachment hole

16—Strut

18—Centering guides

20—Minimum gap guides

22—Node

24—Node fin

26—CEP (Chord End Piece) variant

28—Set-molted Chord

30—Hollow node fin adaptor

32—Node attachment hole

34—Hollow node fin adaptor variant

36—CEP (Chord End Piece)

38—BEP (Beam End Piece)

40—Beam attachment hole

42—Node tin slot

44—Fastener hole

46—Beam

48—SEP (strut end piece) adaptor

50—Strut attachment hole

52—Vertical wall

54—Ball attachment

56—Lock nut

58—Solar frame

60—Top Chords

61—Top layer

62—Mating surface

64—Friction welded area

66—Horizontal walls

67—Apparatus for transferring

68—Torque Plate

70—Torque plate pin hole

72—Primary plate

74—Secondary plate A

76—Torque plate bearing

77—Apparatus for attaching

78—Attachment bolt

79—Upper portion

80—Attachment flange

81—Bottom

82—Torque plate attachment holes

83—First cross arm

84—Lift hole

85—Second cross arm

86—Flange seat

88—Lifting fixture

90—Attachment flange variant

92—Torque plate pin

94—Adjustable pin plate

96—Secondary plate B

98—Bolt guard

100—Non-adjustment pin plate

102—BEP (beam end piece) attachment hole

104—Beveled edge

106—Adaptor slot

108—Adjustment knobs

110—Laser holder

112—Friction tab

114—Laser

116—Alignment arid

118—Laser beam

120—Laser receiver

122—Mirror

123—Platform

124—Truck

126—Air supply tube

128—Scissor support, arms

130—Blower duct adjustment power cylinder

132—Guide rails

134—Camera & proximity sensor

136—Blower & motor

138—Scissor support arm power cylinder

140—Blower duct

142—Pylon

144—Mirror blower assembly

146—Guide rail springs

148—Solid Node torque plate 68 connection (welded)

150—Deformation of hollow center portion

For clarity, the following description will utilize the element numbers(noted as #) and figure numbers (noted as Fig. #). For communicationpurposes, the various items in this patent application can be groupedinto the following categories (please note that some items from onecategory (for example, strut end pieces 10), such as fastening means(pins, bolts, rivets, adhesives. Inertia Friction Welding , frictionstir welding, even how some of the end pieces fit into the longerportions (struts 16/chords/beams 46, etc.) may apply equally well toother listings (for example chord end pieces 36) but will not becompletely re-explained in each description):

1. Strut end piece 10/strut designs: Many of the components of the WESCSP solar frame 58 design share common design features. In prior patentapplications WES disclosed the various designs of struts 16, chords andbeams 46; while some of these were configured as single pieces withfastening holes, many of the designs utilize a long tubular centralportion (strut 16, for example) with one or two end pieces (strut endpieces 10, for example) fastened to the ends. The same design philosophycan be used for chords, beams 46 or potentially other structuralmembers. For simplicities sake, the remainder of this description willuse the terms “strut” and “strut end piece”, although the same conceptcan be applicable to the other types of members.

In conventional space frames or trusses, the end connection of thestruts 16 either to other structural members or to intermediate nodes 22is critical, as the forces which are carried by the members must betransferred through the parts ends. Single piece struts, for example,can have pinned, riveted, bolted or otherwise fastened (mechanicallyinterlocking, adhesively bonded, welded, etc.) connections (again, forthe sake of simplicity, these will be called “pinned” for thisdescription).

For simplicity, struts 16 loaded in a pure axial fashion are discussed(no moments applied to the members); this is often the case in the typesof space frame designs used by CSP parabolic trough solar frames 58. Inthis document, Chords will also most often designate primarily axiallyloaded members while beams 46 often have side loads and moments appliedto them (in the case of CSP frames often from the actual mirror 122weight and mirror 122 wind loads attached to the beams 46). The axialforces carried by the strut 16 must be transferred to the pins (or otherfastening means) and through these to the mating part (often a node 22).During component design analyses, it is important to ensure that thestrut 16 and connection are designed to withstand these axial forces(reference requirements in the 2010 issue of the Aluminum Design Manualpublished by the Aluminum Association—widely recognized and used toguide designs of aluminum structures).

Where single piece struts 16 are used, the pins fastening these to theassociated nodes 22 create healing stresses on the strut 16 materialsurrounding the pins (whether the struts 16 are in axial tension orcompression). As the wall thickness decreases, the bearing stressincreases, so decreasing wall thickness can be a tradeoff with thenegative effect of increasing bearing stress. Wall thicknesses of thestrut 16 must also be consistent with the manufacturing capabilities ofstrut 16 production (greatly reduced wall thicknesses can often increaseextrusion difficulty and cost of an extruded aluminum strut 16, forexample).

Prior WES patent applications have shown detailed designs of strut 16profiles to enhance the overall performance while reducing manufacturingand material cost (for example, the “Apple” strut 16 disclosed in patentapplication Ser. No. 12/798,757). The WES extruded strut end pieces 10are designed to be fastened to the struts 16 with two or more pins (orfastened by other means), reducing the bearing stress per pin and thusdecreasing the wall thicknesses required, while maintaining theassembly's capability to carry the overall axial loads; locallythickened, strut 16 walls coupled with using multiple pins fastening thestruts 16 to the strut end pieces 10 has been used as one way to ensurethat the assembly performs adequately and that overall costs are keptlow. The axial loads are thus transferred through the strut 16 walls tothe multiple pins, and the extruded strut end piece 10 can then transferthe load to a single, larger diameter pin, acting on the strut end piecefins 12 which can be much thicker than the strut 16 walls (the strut 16can be 4, 5 or more feet long while the strut end piece 10 is often onlycut to a length of a few inches, so thicker fins add little to theweight (cost) of the structure as compared to having thicker strut 16walls required at the fastener location.

This patent application will cover further enhancements to the strut 16and strut end piece 10 designs (and beam 46/beam end piece 38 andchord/chord end piece 36 designs as well), designed to tradeoff endpiece design and fastening means to the strut 16 with a more optimalstrut 16 profile design.

The concept is to utilize adhesives. Inertia Friction Welding, frictionstir welding, intermediate pieces or other means to spread the fasteningload required to connect the end pieces to the longitudinal member(strut 16, chord, beam 46, etc.); by doing this, the strut 16 wallthickness can be kept as close to a consistent, thin, wall thickness aspossible for the entire strut 16 profile, minimizing the overall weight(cost) of the strut 16. Similar to the discussion above, the end pieceis then designed to transfer the longitudinal member's axial load to thepin connecting the thicker end piece fins to the associated node 22connection.

-   -   a. Adhesive Bonding. FIGS. 1-16 illustrate various end piece        design details for adhesive bonding; some of these design        details will certainly be applicable to other fastening methods.        Adhesively bonded joints work very well when the bond is loaded        to induce shear within the bond material; bonded surfaces        subject to tension, cleave or peel can also be accommodated, but        not as readily. Adhesively bonded joints function well within a        defined range of bond material thicknesses (for example, for a        particular substrate and adhesive material, the ideal joint        could be between 0.008″ and 0.015″ (although thicker and thinner        joints can often be accommodated)). The designs shown in the        figures utilize very thin raised portions 20 around the        periphery of the end piece which help to prevent the end piece        from “crowding” against one side (wall) of the longitudinal        piece.        -   As disclosed in earlier WES patent applications the            fastening of the end pieces to the longitudinal members can            be accomplished by inserting the end pieces into the            longitudinal member, perhaps in a jig of some sort, with the            end pieces “joined” (pinned, bolted, adhesively bonded, etc            . . . ) to the longitudinal members. If the pieces are to be            mechanically pinned or otherwise fastened, the mating holes            can (but need not be) placed through both the longitudinal            member and the end pieces while clamped together to allow            for easy alignment and insertion of the pin(s) or            fastener(s). Subsequent drilling, piercing or otherwise            creating the hole for the pin or fasteners connecting the            end pieces to the node fin(s) 24 can then be done to the sub            assembled unit to ensure that the hole to hole distances            between the end pieces are not subject to a buildup of            tolerances.        -   The end piece can be manufactured by various means. The            design shown in the figures could be east, die east, impact            extruded or produced by other means. Depending on the            capabilities of the production process, features such as the            secondary internal wait shown in FIG. 7 can be incorporated            to allow adhesive bonding of both the inside and outside            surfaces of the longitudinal pieces (struts 16, chords,            beams 46, etc.). The particular design shown is very deep,            and would likely be difficult to produce, but other,            shallower (from top to bottom as shown) depths would be            possible. The other characteristic of this type of design            feature is to assist in centering the longitudinal member.        -   FIGS. 1-5 envision an end piece which slides inside of the            longitudinal member while FIGS. 6-14 envision an end piece            into which the longitudinal member is inserted (note the            shallow “bond thickness” spacing designed in (FIGS. 8-10).            The final design of how the inner or outer cups transition            into the “fins” which attach to the node fin(s) 24 is a            matter of structural design and manufacturing method (some,            such as impact extrusion, are best suited to more “stepped”            transitions (best seen in FIGS. 2, 6 and 10) while others,            such as casting or die casting, may be better suited to            designs where the “cup” more smoothly “flows” into the            fin(s)).        -   Adhesively bonded joints rely on the bond material,            substrates, cleanliness and/or preparation of the substrates            and the total bond area (square inches of bond) for example.            The designs shown in the associated figures contemplate a            tubular longitudinal member and a cup-like end piece, but            the longitudinal member profile and end piece can certainly            vary. It is certainly conceivable to utilize an adhesively            bonded extruded end piece (such as those shown in prior WES            patent applications) or even a combination of adhesively            bonded and mechanically interlocked (the longitudinal member            could have raised “pips” in or on it that keep the end piece            from rotating in compressive loading applications) or            fastened (pinned, bolted, riveted or otherwise fastened) in            combination with the adhesively bonded components. FIGS.            15-23 illustrate an internal or external “cup” which could,            for example, be inserted into or around a chord member,            either directly allowing pinned (or other) field fastening            to a node 22 or to an intermediate member itself attached to            the node(s) 22. Design features can be incorporated to            utilize pinned (riveted, bolted, etc,), adhesively bonded or            a combination of the two for the connections. FIGS. 20-23            show how a hollow node 22 and intermediate pieces can be            utilized to provide a fin along the axis of the node 22 onto            which a longitudinal member, with or without an end piece,            can be fastened.        -   Various adhesives are possible, but for simplicities sake            3M's 2 part adhesives, “DP920” and “DP420” will be            discussed, both of which exceed the strength requirements of            the applications described herein.        -   As an example, a 3″ diameter strut 16 with a 1″ bond overlap            which would see loads varying from 5800 lbs of tension to            5800 lbs of compression on the strut 16/strut end piece 10            assembly was considered. The adhesive material was tested up            to 140° F. (maximum desert ambient conditions are 134° F. in            the western hemisphere). Using a 1.95 safety factor, this            would require 1,200 psi of shear strength from the adhesive.        -   Aluminum samples were tested with a 0.005″ bond thickness, a            48 hour room temperature cure followed by 2 hours at 140° F.            at 140° F. the DP420 samples achieved 2379-2867 psi shear            strength (2617 average) and the DP920 samples achieved            1335-1359 psi shear strength (1344 average).        -   In this application, the centering guides 18 and minimum gap            guides 20 ensure that the strut 16 is centered-vs-the strut            end piece 10 with a minimum gap of 0.005″. The adhesive is            applied, the strut end pieces 10 are slid onto the strut 16            twisted slightly to distribute the adhesive and the assembly            is clamped for the required “time to handling strength”            (varies by adhesive). Because the bonding will occur in the            extrusion/fabrication factory (not on site at the solar            field), and the strut 16/strut end piece 10 assemblies must            then be transported to the solar field site, the time to            full cure is grossly exceeded.        -   A bond thickness of 0.005″to 0.012″ is preferable. The            adhesive selection was based on no special cleaning or            surface preparation of the aluminum substrates.        -   A strut 16 or chord may be adhesively attached to a node 22            directly. For instance, this could be accomplished using a            Gossamer-style node 22 with segmented chords 28 or chord            connectors, perhaps using only adhesives OR adhesives and a            pinned joint to reduce part of the load requirement aim the            pinned connection (thinner walls/smaller diameter pin, etc.            due to the adhesive taking part of the load). The other            advantage of using the pin and the adhesive is that the pins            could help to hold the parts while the adhesives cure    -   This same logic could be used for a strut 16 connection, using        either a Gossamer style node 22 or a WES “hybrid node” to reduce        deformation under load due to the through chord again, this        could be used with or without a pin.    -   b. Rotational Welding (Inertia Friction Welding). FIGS. 24-25        show how an end piece can be welded onto the longitudinal member        (either conventional welding or via inertial friction welding,        where one member rotates against the other to generate the        necessary heat to accomplish the weld).    -   c. Friction Stir Welding. FIGS. 26-27 show how an end piece can        be welded onto the longitudinal member via friction stir welding        where a rotating tool “disturbs” the base metal of the end piece        and longitudinal member, “mixing” them together (the process and        tool are not shown just the parts before and after joining via        FSW.        -   Both Inertial and Friction Stir Welding techniques are            existing joining technologies used for various materials.            Both of these joining techniques can be used for joining            struts 16/chords to their end pieces, for instance for solar            frame 58 applications.        -   Both Inertial and Friction Stir Welding use no weld            material,        -   Inertial welding as applied to struts 16/chords and end            pieces would use the struts 16/chord rotating-vs-the end            pieces. The high speed of rotation coupled with forcing the            two parts together creates heat which melts the base            material. Rotation is stopped at a precise time to assure            rotational alignment,        -   Friction Stir Welding uses a rotating steel tool, often with            a pointed end on it, which rotates at the interface between            the parts to be joined, melting and mixing” of the base            materials of the two parts.        -   In some applications the two base materials melt together            and solidify, in others, like FSW, it is more of a “plastic”            “forging/mixing” together of the base materials.

2. Beam end piece 38. As noted previously, Strut 16 and Chords generallyundergo axially loading as part of their designs incorporating nodes 22(there is some MINOR side loading and moments from the weight of theserelatively light members and any wind loads acting on them directly).Beams 46, on the other hand, generally see quite large side loads andmoments due to the weight and wind loads associated with the reflectivesurfaces which depend upon them for support. The pan designs depicted inFIGS. 28-39 provide greatly enhanced part efficiency in handling theseadditional (beyond axial) loads. The additional side loads can beenvisioned in FIG. 33 if the reader assumes that the reflective surfaceis mounted above the beam 46 and is thus either pushing downward on thebeam 46 or lifting up on the beam 46. The beam end piece 38 design showncan be adapted for use with other components (chords or struts 16) aswell.

Some designs of strut end pieces 10 and chord end pieces 36 shown inprior WES patent applications are shown as having been produced fromextruded aluminum, as is this beam end piece 38 design. The differenceis that in the prior designs, the fin(s) are produced in the directionof extrusion through the extrusion of aluminum through a die, while the“fins” shown in FIGS. 28-39 are produced by machining or otherwiseremoving material from the extruded end piece. The fastening holes shownon the bottom legs can attach to the longitudinal piece (beam 46, forexample) via pins, rivets, bolts or other fasteners, or these legs canbe adhesively bonded or otherwise joined as discussed previously in thepatent application. The fastener hole 44 for attaching the end piecefin(s) to the node fin(s) 24 can be, extruded into the piece during theextrusion process, drilled or pierced after extrusion or extruded andsubsequently drilled/pierced/boned, etc, depending on the requirements.

The main feature which enhances the efficiency of die beam end piece 38in this application is that the full cut length of the extruded endpiece is resisting the side load-vs-just the extruded fin thickness inprior designs showing an extruded end piece. FIGS. 36-43 illustratealternative means to create end pieces (shown utilizing fins) forlongitudinal members using an additional transition piece (FIGS. 39-43)which can be fastened to the portion which attaches to the node fin(s)24 and to the longitudinal member (both of these connections can bepinned, riveted, bolted or otherwise joined, adhesively bonded or viausing a combination of these approaches. The length of the transitionalpiece can be varied to provide more bonding surface along the length ofthe longitudinal member, as required by the load requirements of thepart, the adhesive utilized, the substrates and their preparation(surface finishing, cleaning, etc.).

FIGS. 41-51 illustrate the design of and end piece (with fins) andassociated transitional piece designed to be adhesively bonded to thelongitudinal member. The portion with the fins that attach to the nodefin(s) 24 can be adhesively bonded to the intermediate part which inturn can be adhesively bonded to the longitudinal member (the purpose ofall of these intermediate members is to allow the long, longitudinalmember to be as simple/light as possible if the longitudinal tube hadcomplex hollows such as the intermediate piece, it would be MUCHheavier—in addition, the extrusion difficulty increases, slowing theextrusion velocity and further increasing the cost of the part.

FIGS. 52-57 and 58-63 illustrate how different types of end pieces canbe utilized with this system (intermediate parts). The designillustrated in FIGS. 52-57 would be well suited to accept side loadssuch as might occur in a beam 46 and beam end piece 38 subassembly. Thedesign illustrated in FIGS. 58-63 would be better suited for primarilyaxial loaded, longitudinal members (where the node 22 could incorporateperhaps a “socket” design). FIGS. 64-72 illustrate an end piece designwhich could be easily extruded and cut to length and which could beadhesively bonded to the intermediate piece 9 a third leg is shown toallow greater bonding area of the end piece to the intermediate piece);the intermediate piece could then be bonded to the longitudinal member.

Double fin Design for solid node 22

This design allows for a strut 16 to be attached to our solid node 22with or without the use of a strut end piece SEP 10. The benefits of thesolid node 22 over the hollow node 22 have been explained in detail inU.S. patent application Ser. No. 12/927,813. FIGS. 147 through 150 showFEA results for the double fin solid node and the double fin hollownode. In this comparison each node 22 was loaded in the same manner. Acompression load of 5,000 lbs was applied to each of the side fins toshow how the hollow would deform in such a case. The solid node 22resulted in 57.5% less maximum stress in the part and 41.8% lessdeformation then the hollow node in this case. The hollow node is stilla viable design for some of the connection points of the frame.

3. Torque plate 68 designs. FIGS. 75-78 illustrate a torque plate(s) 68design (currently designed utilizing plate steel). This design utilizesnodes 22 at the inside top vertices and bottom vertex of the framegeometry (refer to FIG. 74). providing two functions—supporting theframe on either end in a bearing mounted to the pylons 142 on either endand allowing one frame to be fastened to the next so that a drivemechanism rotating one frame can also rotate the frame adjacent to it,and that to the one adjacent to it, for a total of from two framesjoined together to more than two (CSP parabolic trough designs in usehave between 4 and 6 frames on either side of the drive driven by thedrive, although this number can be greater or lower depending on systemdesign considerations). FIGS. 75-78 illustrate how the torque plate 68behind and slightly above the front torque plate 68 (FIG. 76) has awelded tube attached to it with a flange on the end of the tube. Thetorque plate 68 attaches to the end of the frame via nodes 22 thatfasten to the ends of the cross arms and the bottom of the cross. Theflange has holes in it which correspond to holes on another torque plate68 intended to be fastened to an adjacent frame,

The bolted connections between the flange and the next torque plate 68allow for slight rotational alignment of one frame to another. Oneintent is to have a torque plate 68 attached to each end of each framewhen it is assembled, and to contemplate lifting the assembly viaattachment brackets (FIGS. 79-83) which attach to each of the torqueplates 68 upper edges. This method of assembly allows easylifting/manipulation of the assembled frames with torque plates 68 ontothe line of pylons 142 that they are mounted on as mentioned, the boltedconnections on the flange can allow rotational adjustment/alignment ofthe frames. FIG. 86 illustrates one of a large number of differentgeometries/number of fasteners defining the connection between theflange and the torque plate 68 (trading off number and size offasteners, torque carrying capability. etc). FIGS. 87, 88 and 89illustrate a torque plate 68 design which incorporates a fastened(-vs-cut from one piece) arm assembly which allows for frame adjustmentand allows for the frame to be lifted from the torque plate $8 on oneside of the frame and the arm assembly from the other end; it alsoincorporates thick structural pin(s) which could be inserted into hollownode(s); this type of system would typically be employed where the firstframe to be attached to a drive unit side would have a single torqueplate 68 on the drive side of the frame, with a double torque plate 68minus the arm assembly 96 on the other end. The next frame would havethe arm assembly 96 on one end (which would be attached to the doubletorque plate 68 of the first frame via these pin(s) and a “double torqueplate” attached to the other end (minus arm assembly—96). The processrepeats until the last frame associated with the line of frames has onlya single torque plate 68 attached to its far end. The curved guide shownin FIG. 89 is intended to, protect the bolt heads from the pylon 142.

FIGS. 90-92 illustrate an adjustment pin plate which allow rotationaladjustment between one frame and the next (the pin plate has some roundand some slotted holes). FIGS. 93-102 illustrate a straight (-vs-crossshaped) torque plate 68 design which could be associated with adifferent frame geometry.

4. WES frame geometry and design. FIGS. 73 and 74 illustrate a “series5” WES design (5 triangles as viewed from the end). This design wasfirst shown in patent application Ser. No. 12/583,787; the purpose ofillustrating it again in this patent application is to demonstrate that.this design utilizes four top chords 60.

Benefits of a frame with four top chords 60 vs. three top chords 60:

A 4 chord system allows for the beams 46 to more closely match theparabolic shape of the mirror 122 surface. This allows for shorterconnections between the beam 46 and mirror 122 rail, which reduces theforces applied to the beam 4$ resulting in lighter members, brackets,and fasteners. The total length of members needed to connect to themirrors 122 is reduced up to 18.5% by using a 4 chord system compared toa 3 chord system.

A 4 chord system creates three beams 46 instead of two. These beams 46have a shorter span which allows for smaller sections compared to a 3chord system. This is also true for some of the struts 16. The beam 46spans for a 4 chord system, are between 10-30% shorter than the beam 46span for a 3 chord system.

A 4 chord system allows for two connections to the torque plate 68 atthe top layer instead of one. The torque at the end of the frame isdistributed over more connections/members resulting in a lighter andpotentially more rigid frame. The forces at the torque plate 68-to-nodeconnection are 37-80% smaller for a 4 chord system compared to a 3 chordsystem.

Specifically, the beams 46 and struts 16 in a 4 chord system can spanbetween 40 and 200 inches. The range for the force at the torque plate68 is greater than 1,800 lbs. to 10,000 lbs. and up to 32,000 lbs. Thisis the shear force located at the connection between the torque plate 68and the nodes 22. The minimum torque load for a single torque plate 68is about 150,591 in-lbs. the maximum is 2,520,842 in-lbs. (6,250,000in-lbs. for hurricane prone regions). Typical would be about 700,000in-lbs.

The purpose of these two-piece torque plate 68 designs is to allow theattachment of both torque plates 68 to the frame during the assemblyprocess. This then allows the frames to be lifted and placed by thetorque plates 68 and then adjusted for frame to frame alignment which isnot possible with other frames. To accommodate such constraints, theplate thickness is about 9/16″ and the size of the plate has thedimensions shown in FIG. 75. The top four chords have axial force limitsof a min. of about 500 lbs. and a max of about 20,674 lbs.

5. Frame-to-frame laser 114 alignment. FIGS. 103-112 illustrate aframe-to-frame alignment system designed to utilize laser 114 alignmenttools with tubular frame designs. The particular design shown is for atubular node or longitudinal member utilizing at least two sides atright angles to each other (ID of the tube), although other designs forother profiles could be easily adapted. The intent is to slide theholder shown in FIG. 103 into the ID of the longitudinal member, and toplace a laser 114, such as those used to be placed into the bores ofrifles or other munitions' bores, into the holder. A “receiver” is slidinto the ID of the opposite end of the longitudinal member. Note thatboth the laser holder 110 and receiver 120 have flexible membersdesigned to “flex” and “crowd” the part toward one side of thelongitudinal members ID.

The laser 114 projects a spot onto the grid of the receiver slid in tothe other end of the longitudinal member, and the adjustment wheels ofthe holder are adjusted such that the spot is centered about the axisthat the laser 114 is mounted within. The receiver 120 is then removedfrom the end of the longitudinal member and placed into the near end ofthe longitudinal member of the next frame's associated part. Note thatboth ends of the receiver 120 have identical mountings, including theflexible “crowders” to facilitate moving from one frame to another. Thelaser 114 spot deployed onto the grid of the receiver 120 in the secondframe thus shows how this frame must be adjusted to come into alignmentwith the frame that the laser 114 and holder are associated with. FIGS.110-112 show this, but the frames in FIG. 112 are shown much furtherapart than they actual are mounted. The torque plate 68 of the leftframe would be adjacent to the pylon 142 that has the right framemounted on it—this distance allows the dotted line indicating the pathof the laser 114 to be envisioned.

The. frame laser 114 alignment tool holder, shown in FIGS. 101406, has alaser 114 such as used in rifle bores inserted into its central “laserholder” 110; FIG. 106 shows the laser 114 inserted into the laser holder110 of the laser 114 alignment tool holder. Because there aremanufacturing tolerances in the solar frame 58 structural tube (chord,beam 46, mirror 122 rail, etc.) inside dimensions, for example, thelaser 114 alignment tool holder is designed with flexible friction tabs112. As the operator inserts the laser 114 alignment tool holder intothe structural tube of the frame, the friction tabs 112 are squeezedinwards providing clearance to slide the holder into the tube. When theoperator releases this squeezing pressure, the friction tabs 112 expandback outwards from the central laser holder area 110, in effect“crowding” the laser 114 alignment tool holder to the opposite side.Because there are two of these friction tabs 112 for the specific designdepicted in the patent application for a rectangular tube, these “crowd”the laser 114 alignment tool against two right-angled walls of the ID ofthe structural tube. Any variation in ID dimensions occur at theflexible laser holder 110 sides of the tube; this ensures that the laser114 alignment tool has its central laser holder 110 at a fixed dimensionfrom each of the two right angled ID wails of the structural tube.

The receiver 120, shown in FIGS. 107-109, uses flexible friction tabs(112) in a similar manner to the laser 114 alignment tool holder.Because both the receiver 120 and the laser 114 alignment tool holderare thus “crowded” to the same two sight angled adjacent sides of thestructural tube ED, variations in the tube ID are negated. For initiallaser 114 alignment. tool holder calibration, both it and the receiver120 are placed into opposite ends of the same frame structural tube. Thereceiver 120 uses an alignment grid 116 so that the laser beam 118 unitinserted in the holder can project a beam 46 onto the receiver 120.Referring back to the laser 114 alignment tool holder, the adjustmentknobs 108 allow the angle of the laser 114 alignment tool holder to beadjusted until the laser beam 118 is centered onto the receiver'salignment grid 116. The receiver 120 is then moved to the next framesstructural tube (note that because the receiver 120 has two identicalends utilizing friction tabs 112 on either side of a bisecting verticalplate (see FIG. 107). the receiver 120 can be moved longitudinally fromone frame's tube to the next frame's tube WITHOUT having to turn it 180°and losing the alignment relationship to the laser 114 alignment toolholder). The adjacent frame can then be adjusted to best align it to theframe containing the laser 114 alignment tool holder with the laser 114in its bore; the laser beam 118 projected onto the receiver 120 in theend of the adjacent frame can be used to indicate frame-to-framerotational alignment. All of these concepts can be seen in FIGS.103-112.

6. Mirror 122 cleaning system which avoids water use. The systemillustrated in FIGS. 113-131 was originally designed to allow highvolume air flow to be applied to the curved parabolic reflectors toremove desert dust or other debris which partially obscures and reducesthe efficiency of the light focus onto the system's collector tubes; itcan also be adapted to incorporate water or other liquid in addition to,or as a replacement for the anticipated air flow. The system as shown inthe figures (perhaps best understood by reviewing the top vie in FIG.113 and the isometric view mounted on the truck 134 in FIGS. 126 and127) allows an air compressor, squirrel cage fan or other means toaccelerate and provide high volume pressurized air through a tube to amultitude of nozzles (or a long slotted singular nozzle (or a few ofthese)) and a means to position these nozzle(s) dose to the edge of thereflectors safely. The assembly is manipulated toward and away from theside. of the truck 124 by a scissors mechanism likely utilizing photoeyes and/or spring or pneumatic (or hydraulic) absorbing means (orpolymers providing the same function) such that guides never contact theframe with more than desired force. The portion of the guide which is infront of the air system (again, refer to FIG. 127, for example), isangled inward slightly toward the truck 124 so that the edge of theguide never hits the end of the frame directly, but instead graduallyengages with the frame as the truck 124 moves forward.

The system can easily be design with shear pins or other means to ensurethat the cleaning mechanism or its mountings fail prior to any framecomponents in the event that there is a collision between the device anda frame; this design would incorporate easily replaceable parts tominimize repair costs and lost time in the field. FIG. 129 shows how theguiding means are intended to utilize the pylons 142 as “guides”; withthe frame tilted properly for the cleaning process, the truck 124progresses forward as the air stream blows the offending particles alongthe parabolic reflective shape and off of the assembly (over the truck124). FIG. 122 shows the front view detail of the blower duct 140 andguides as well as the proximity sensor 134 to avoid collisions with thepylons 142.

FIGS. 113-131 depict a truck 124 mounted mirror 122 cleaning systemdesigned to protect the parabolic frames and mirrors 122 and to properlyclean them using high velocity air-vs-water (the system can be adaptedto use water as well, but the design was originally created to limit theuse of scarce water in arid environments). The truck 124 has mounted toit an air blower and motor 136 which generates high velocity air; thisis ducted through the air supply tube 126 to the blower duct 140 whichwill be adjacent and mostly parallel to the mirror 122 surface, ensuringthe delivery of high velocity air onto the parabolic mirrors 122surface. The intent is to have the truck 124 drive along thelongitudinal direction that the parabolic mirror frames are placedalong. These frames are mounted to pylons 142 which support and guidethe frames as they rotate to follow the sun; the frames are generallyconnected frame-to-frame in solar collector arrays (SCA) driven bycommon drive means (generally 4-6 frames on either side of a commondrive, with thus 8-12 frames turned by the drive). SCA's are turned inunison by adjacent drive units—the collector tubes which the parabolicmirrors focus sunlight onto are thus basically aligned over the courseof perhaps ½ to 1 mile in length. The truck 124 can thus be positionedand can basically drive for ½ to 1 mile in a straight line with theblower ducts 140 providing high velocity air to the mirror 122 surfaces.The blower and motor 136 would have air filters removing any dust toensure that the high velocity air doesn't include particles which coulddamage the reflective surfaces. The air supply tube 126 can betelescoping or festooned using flexible tubing to allow for adjustmentof the mirror blower assembly 144-vs-the pylons 142 and mirror surfaceblower assembly 144 is made up of the blower duct 140, guide rails 132,camera and proximity sensor 134 and guide rail springs 146). The highvelocity air blows surface sand, dust and debris off of the mirror 122surface; the blower duct adjustment, power cylinder 130 is used toadjust the angle of the high velocity air to the mirror 122 surface. Theparabolic mirrors 122 are extremely large/wide and thus the exiting airoff of the mirror 122 surface is 18 or more ft. in the air (see FIG.131).

The mirror 122 surfaces (can be glass, laminated polymers, polishedmetal, etc) must be protected from the blower duct 140 or othercomponents physically touching them. FIG. 118 shows an isometric view ofthe blower, ducting and blower duct 140 system as well as the scissorsupport arms 128 and guide rail 132, camera and proximity sensor 134.FIG. 120 shows the, guide rail springs 146. The truck 124 driverpositions the blower duct 140 parallel and in close proximity to thepylons 142 (see FIG. 129). The camera and proximity sensor 134 monitorthe distance between the guide rail 132 and the pylons 142, signalingthe scissors support arm powered cylinder 138 to extend or retract thescissors support arms 128 and the mirror blower assembly 144 (attachedguide rail 132 and attached blower duct 140, etc.); this occurscontinuously to ensure that the spacing between the cleaning system andthe pylons 142/frames/minors 122 is maintained properly. in addition,the guide rail springs 146 shown in FIG. 120 are an additional safety sothat if, for example, the truck 124 were to swerve slightly off of astraight line and impact the pylon 142, the springs would take up theimpact; FIG. 123 also shows how the guide rails 132 have its leading ½angled slightly inward to ensure easier guidance of the system, furtherreducing the likelihood of any mechanical contact

The blower assembly may automatically position itself relative to thepylons 142, frames and mirrors 122. There may be an impact avoidancemechanism disposed on the truck 124 to avoid impact by the truck 124with the pylons 142, frames and mirrors 122 as the truck 124 moves. TheTough Sonic/PC Distance sensor (TSPC-30S1 series) with the Senix VIEWsoftware and an Elite monochrome camera (BE-200C) is one example of anexisting product that may be added to the blower :assembly and the truck124 to provide for automatic positioning of the blower assembly and foravoidance of the pylons 142, frames and mirrors 122 as the truck 124moves. The Elite BS-430AW-KXP sensor system may also be used inconjunction with the Tough Sonic for these purposes.

7. Torque plate 68 Node Designs. FIGS. 132-142 illustrate node assemblydesigns to transfer the loads from the frame nodes 22 attached to theends of the frame and to the torque plates 68. This design minimizes theinduced moment in the node 22 due to the forces convergence point beingcloser to the torque plate 68. This allows for a lighter node 22. Indesigns where multiple frames are driven by a single drive unit, theframes on either side of the drive unit are subjected to the highesttorques and thus the highest loads on these connections. The node 22assembly shown in FIGS. 133, 134 and 141 is a hollow node which engageswith and is fastened to a structural pin extending from the torqueadjustable pin plate 94. The assembly shown in FIGS. 135-139 and FIG.142 is a solid node welded to a back plate (alternatively, it could beinserted into a hack plate water jet cut or otherwise processed toaccept insertion of the node 22 profile, and then welded onto both sidesof the plate it needed. The plate is then bolted onto the torque plate68.

The “welded node” was designed to bring the point where the struts 16and chords intersect as close as possible to the plane of the torqueplate 68. Because of the width of the chords and struts 16, there willalways be a slight offset. This offset creates a moment within theattachment node 22. By using the solid or hollow node welded to theattachment plate which then bolts to the torque plate 68 this offset isminimized, thereby minimizing the weight of the node 22 and attachmentplate required. The perimeter weld shown in FIG. 136, for example,provides more structure than, a pinned connection which would extendthrough the torque plate 68 into the ID of the hollow node such as shownin FIG. 133; the wider connection provided by the weld-vs-the pinprovides more resistance to twisting the node 22 relative to the planeof the torque plate 68.

Although the invention has been described in detail in the foregoingembodiments for the purpose of illustration, it is to be understood thatsuch detail is solely for that purpose and that variations can be madetherein by those skilled in the art without departing from the spiritand scope of the invention except as it may be described by thefollowing claims.

1. An apparatus for transferring force to a frame of a solar mirrorarray, the frame having at least one structural element, the apparatuscomprising: a torque plate; and at least one node attached to and incontact with the plate which connects with the structural element. 2.The apparatus of claim 1 wherein the node has at least. one finextending from the node's outer surface.
 3. The apparatus of claim 2wherein the node has a solid central portion,
 4. The apparatus of claim1 wherein the torque plate can withstand a force greater than 1,800 lbs.5. The apparatus of claim 4 wherein the torque plate can withstand aminimum torque load of about 150,591 in-lbs.
 6. The apparatus of claim 5wherein the plate thickness is about 9/16″.
 7. An apparatus forattaching a primary solar mirror frame array with a secondary mirrorframe array comprising: a primary torque plate having. an upper portionand a bottom; a secondary torque plate having an upper portion and abottom; and a torque plate bearing attached to the primary and secondarytorque plate through attachment flange of the primary and secondarytorque plate, the primary and secondary torque plates attach to an endof the primary and secondary frame, respectively, via nodes of theframes that fasten to the upper portions and the bottom of therespective plates, the flange between the primary and secondary torqueplates allows for rotational alignment between the primary and secondarytorque plates.
 8. The apparatus of claim 7 wherein the primary torqueplate has an attachment flange and the secondary torque plate has amatching hole pattern to that of the primary torque plate's attachmentflange, and the bearing attached to the primary and secondary torqueplate through the attachment flange of the primary and secondary torqueplate.
 9. The apparatus of claim 7 including a first lifting bracketattached to the primary torque plate and a second lifting bracketattached to the secondary torque plate for lifting the frame via theprimary and secondary torque plates.
 10. The apparatus claim 7 whereinthe primary torque plate has a cross shape.
 11. The apparatus of claim10 wherein the upper portion of the primary torque plate has a firstcross arm and a second cross arm.
 12. A solar trough frame for holdingsolar mirrors comprising: a plurality of chords which include a toplayer of only 4 chords essentially in parallel with each other; aplurality of struts; a plurality of nodes that connect to the struts andchords, and a platform supported by the chords and struts on which thesolar mirrors are disposed.
 13. The frame of claim 12 wherein the fourchords of the top layer have axial force limits of a minimum of about500 lbs.
 14. The frame of claim 13 including a torque plate having twoconnections to the top layer.
 15. The frame of claim 14 wherein the fourchords of the top layer have axial force limits of a maximum of about20,674 lbs.
 16. The frame of claim 15 wherein at least one of the fourchords of the top layer is one continuous piece that extends the framesentire length.
 17. The frame of claim 15 wherein at least one of thefour chords of the top layer is formed of segmented chords that togetherextend the frames entire length.